03/12/2013
Z.R. Tool Inc. - ZL90 Manual
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1. To remove gripper, use drift pin matching the dimension of the spring tension pin (position
38) and drive the spring tension pin into the tool base, until the gripper comes loose from
its position.
2. Lift feedwheel lever (position 7) to access gripper.
3. Clean cavity area and add one drop of a thin grade of oil in the cavity.
4. To install new gripper, place the gripper into the cavity of the tool base. Reinstall the
spring tension pin and drive it into the hole of the tool base, until it is flush with the tool
base.
To Replace The Knife (Position 19)
1. Remove housing cover ZL (position 66), by removing 4 hexagon socket shoulder screws
(position 64)
2. With pliers, pull knife from slot on die and knife block (position 15).
3. Install new knife observing spring tension pin (position 20) aligns with same slot on die and
knife block.
4. Make certain that the area is clean and well greased with white grease.
5
Important: Make certain that the roller (position 78) is in its position.
6. Reinstall housing cover ZL, then reinstall hexagon socket shoulder screws with a drop of
Loctite* No. 222 on the thread of each screw.
To Replace The Punch (Position 36)
1. Remove 2 cheese head machine screws (position 63) located on the underside of the
housing (position 58).
2. Remove punch, clean area, replace with new punch, then reinstall cheese head machine
screws with a drop of Loctite* No. 222 on the thread of each screw.
To Replace The Die (Position 18)
1. Remove housing cover ZL (position 66), by removing 4 hexagon socket shoulder screws
(position 64).
2. Remove sealing lever (position 62), by loosening hexagon socket cap screw (position 61).
3. Remove woodruff key (position 1).
4. Remove eccentric shaft (position 72).
5. Remove the total internal assembly by tilting it at a 20 degree angle (see diagram below)
and pull out with pliers by eccentric shaft plunger (position 76), at the same time making
sure to hold internal assembly together with other hand, exposing die on the underside of
the die and knife block (position 15).
6. Remove 4 cheese head machine screws (position 13).
7. Remove die, clean area, and replace with new die, then reinstall cheese head machine
screws with a drop of Loctite* No. 222 the thread of each screw.
8. To reinstall the internal assembly follow the installation of internal assembly instructions
below.
9. Reinstall the eccentric shaft observing its relative position to the cam (position 45).
10. The cam lever (position 71) must engage with its tip into the cavity of the cam. The
components should align together and operate smoothly, please do not force the parts
together.
11. Make certain that the area is clean and well greased with white grease.
12. Important: Make certain that the roller (position 78) is in its position.
13. Reinstall housing cover ZL, then reinstall hexagon socket shoulder screws with a drop of
Loctite* No. 222 on the thread of each screw.
14. Reinstall woodruff key and sealing lever.
Removal of Internal Assembly ZL90
